Electrical jack and method of making same

ABSTRACT

An electrical jack and method of making the electrical jack wherein a housing is formed with at least one socket for receiving a circuit board edge connector, wherein a circuit card is fixed to the housing and has an end portion extending into the socket for reception in the connector upon insertion of the connector into the socket, and wherein a set of contact spring members are insertable through an aperture in the housing in the process of making the electrical jack. The contact spring members are removably trapped in place against cooperating surfaces on the housing and the circuit card at positions where they cooperate with conductors on the circuit card to normally interconnect two sets of terminals and where they are deflectable by insertion of the connector into the socket to electrically disconnect the two sets of terminals from each other.

This application is a division of application Ser. No. 955,233 (now U.S.Pat. No. 4,256,936) filed on Oct. 27, 1978 for Electrical Jack and PatchCord Assemblies, said application Ser. No. 955,233 being, in turn, acontinuation-in-part of application Ser. No. 650,019 (now U.S. Pat. No.4,140,918) filed on Jan. 19, 1976 for Electrical Jack and Patch CordAssemblies, said application Ser. No. 650,109 being, in turn, acontinuation-in-part of the now abandoned application Ser. No. 420,584filed on Nov. 30, 1973.

FIELD OF INVENTION

This invention relates to electrical switch and connector equipment andis particularly concerned with electrical jacks and patch cord plugconnectors.

BACKGROUND

Prior to this invention various self-normalling electrical jacks havebeen used for interconnecting multi-terminal electrical circuits such asdata communication equipment and computers or other signal producing andutilization equipment. In manufacturing jacks of this type it has been ageneral practice to use discrete wiring or conductor components withplug actuatable contacts to complete the various current conductingpaths through the jack. Such electrical jack constructions are describedin U.S. Pat. No. 3,692,966 (issued Sept. 19, 1972) and in my previouslyidentified copending application Ser. No. 650,019.

In place of the discrete conductor components it has been proposed touse board-mounted printed circuits. These proposals, however, have ledto large, bulky, expensive jack constructions having numerous parts. Thepresent invention has none of these drawbacks and offers additionaladvantages and improvements as will become apparent from the followingsummary and detailed description.

SUMMARY AND OBJECTS OF INVENTION

The plural socket jack embodying the principles of this invention mainlycomprises a printed circuit board or card and a multiplicity or aselected number of circuit-making contact springs. The contact springscontact and coact with printed circuit conductors or elements on theprinted circuit board to establish a multiplicity of mutually insulatednormal through circuits or current conducting paths each terminating atopposite ends in first and second terminals. The terminals of the normalthrough circuits are adapted to be connected to electrical equipment orelectrical circuits located exteriorly of the jack. The contact springsare actuatable by reception of a patch cord plug in the jack to open orbreak the normal through circuits, thereby electrically disconnectingthe first terminals of the normal through circuits from the secondterminals of the normal through circuits.

The normal through circuits may advantageously terminate at theiropposite ends in a pair of multi-terminal connectors. Thesemulti-terminal connectors may, if desired, be mounted directly on theprinted circuit board mentioned above.

The printed circuit board extends into and is detachably secured to aone-piece hollow jack housing or body. The jack housing defines thejack's plug-receiving sockets and is designed so that it canconveniently and economically be molded as one-piece from any suitableelectrical insulating material.

According to this invention the arrangement and construction of theprinted circuitry and contact springs in the jack assembly are such thatthe only discrete electrically conductive components in the entire jackassembly are the contact springs themselves and the terminal connectionsfor the multi-terminal connectors mentioned above. According to anotherimportant feature of this invention the contact springs are trapped andheld in place by cooperating surfaces on the one-piece molded jackhousing and the printed circuit board without being affixed to any partof the jack.

Because of the foregoing jack construction the only fasteners requiredin the entire jack assembly of this invention are those needed forsecuring the printed circuit board to the jack housing and those neededfor mounting the previously mentioned multi-terminal connectors on theprinted circuit board in the embodiments where the connectors aresupported on the printed circuit board itself. In the illustratedembodiments the printed circuit board is rigidly fixed to the jackhousing by only two suitable fasteners such as a pair of screw and nutassemblies.

According to still another feature of this invention the novelconstruction and arrangement of the jack housing and contact springspermit easy installation of the contact springs. Furthermore, thecontact springs can be removed and replaced without removing any otherpart of the jack and also without loosening or removing any fasteners orunsoldering any connections in the jack assembly.

The foregoing jack construction also simplifies the assembly of thecomponent jack parts. In particular, assembly is accomplished by firstinserting the printed circuit board into the one-piece housing andsecuring the housing and printed circuit board together with thefasteners mentioned above. Thereafter, the contact springs are assembledsimply by inserting them through one or more windows or apertures in thejack housing and by positioning them in their operative positions.

In the first illustrated embodiment the contact springs are divided intotwo independently operated sets. One set of the contact springs isdirectly engaged and deflected by the body of a patch cord plug uponinsertion of the plug into one of the jack's plug-receiving sockets toelectrically disconnect the terminals of one of the multi-terminalconnectors from the terminals of the other of the multi-terminalconnectors. The other set of contact springs is directly engaged anddeflected by the body of the patch cord plug upon insertion of the patchcord plug into a second plug-receiving socket in the jack to alsoelectrically disconnect the multi-terminal connectors from each other.This particular construction eliminates the need for separateplug-operated mechanisms of the type that transmits motion to actuatethe contacts in the jack.

In the second illustrated jack embodiment of this invention, a flapengages the contact springs and extends into the two plug-receiving jacksockets mentioned above in a position where it, in turn, is engaged andpivoted by insertion of a patch cord plug into either one of the twosockets. The pivotal motion of the flap deflects the contact springs totheir circuit-breaking positions. This simple flap constructionsimplifies the printed circuit package and reduces the number ofrequired contact springs as compared with the first illustratedembodiment.

According to another feature of this invention each of the jack'scontact springs is permanently bent back towards itself to define twospring arms which act independently of each other. One of the springarms is biased by engagement with a jack housing surface to stationarilyseat against a contact pad in the printed circuitry. The other springarm is arranged for deflection between circuit-opening andcircuit-closing positions and is normally biased to its circuit-closingposition where its free end seats against another printed circuitcontact pad. The deflectible spring arm is arranged and flexed in such amanner to wipe its associated contact pad as it is lifted off thecontact pad and also as it touches down on the contact pad. Wiping thecontact pad in this manner assures good low resistance electricalcontact between the deflectible spring contact arm and the contact pad.

According to still another feature of this invention coacting means areprovided on the body of the patch cord plug and the deflectible contactspring arm mentioned above for releasably locking or latching the patchcord plug in an operative position in the electrical jack. This uniquelatching construction eliminates the need for separate mechanisms of thetype used to releaseably retain the patch cord plug in its operative,plugged-in position in the jack.

According to still another feature of this invention the patch cord plugbody is provided with a novel strain relief cable-anchoring constructionwhich resists tensioning or turning of the patch cord's cable.

With the foregoing in mind, it is the general aim and purpose of thisinvention to provide a novel electrical jack which is relativelyinexpensive to manufacture. Another important object of this inventionis to provide a novel electrical jack which is compactly and efficientlyorganized, which has relatively few parts and which is easy to assemble.

Still another object of this invention is to provide a novel electricaljack which does not require any fasteners, soldering connections or thelike to retain circuit-making contact springs in place within the jackbody.

A further object of this invention is to provide a novel electrical jackconstruction in which all of the electrically conductive components forma part of a printed circuit except for the contact spring elementsthemselves and terminal connections to electrical connectors.

Still another object of this invention is to provide a novel electricaljack construction which permits easy installation and removal of thejack's contact springs.

A further object of this invention is to provide a novel electrical jackconstruction in which the circuit-making contact spring elements aredirectly engaged for deflection by the body of a patch cord plug uponinsertion of the patch cord plug into the jack.

Still another object of this invention is to provide a novel electricaljack construction in which a pivoted flap is engaged by the body of apatch cord plug upon insertion of the plug into the jack to deflect thecontact springs to their circuit-opening positions.

A further object of this invention is to provide a novel electrical jackin which the deflectible contact spring portions are biased and flexedin such a way to wipe their associated stationary contact pads uponlifting off of the pad and also upon touching down on the pad.

Still another object of this invention is to provide a novel electricaljack and patch cord plug assembly in which coacting means on the jack'scontact springs and the plug's insulating body releaseably lock the plugin its operating position in the jack.

A further object of this invention is to provide a patch cord plug witha novel patch cord cable strain relief construction.

Further objects of this invention will appear as the descriptionproceeds in connection with the appended claims and below-describeddrawings.

DESCRIPTION OF DRAWINGS

FIG. 1 is a generally schematic diagram showing the electrical jack ofthis invention and the patch field and monitoring connections that it iscapable of making;

FIGS. 1A and 1B are generally schematic diagrams of the circuitryincorporated into one embodiment of the jack of this invention;

FIG. 2 is a front elevation of the electrical jack shown in FIG. 1A;

FIG. 3 is a left hand side elevation of the electrical jack shown inFIG. 2;

FIG. 3A is an enlarged fragmentary view of the jack construction shownin FIG. 3;

FIG. 4 is a right hand side elevation of the electrical jack shown inFIG. 2;

FIG. 5 is a rear elevation of the electrical jack shown in FIG. 2;

FIG. 6 is a top plan view of the electrical jack shown in FIG. 2;

FIG. 7 is a section taken substantially along lines 7--7 of FIG. 3;

FIG. 8 is a section similar to FIG. 7, but showing one of the patch cordplugs inserted into uppermost one of the sockets in the jack assembly;

FIG. 9 is a section taken substantially along lines 9--9 of FIG. 3;

FIG. 10 is a section similar to FIG. 9, but showing one of the patchcord plugs inserted into the intermediate or middle plug-receivingsocket of the jack assembly;

FIG. 11 is a section taken substantially along lines 11--11 of FIG. 3and illustrates the patch cord plug inserted into the lowermost one ofthe jack's plug-receiving sockets;

FIGS. 12 and 12A are sections respectively taken along lines 12--12 andlines 12A--12A of FIG. 3;

FIG. 13 is a left hand side elevation of the printed circuit board shownin FIGS. 2-6;

FIG. 14 is a right hand side elevation of the printed circuit boardshown in FIGS. 2-6;

FIG. 15 is a front end elevation of the patch cord plug shown in FIGS.8, 10 and 11;

FIG. 16 is a side elevation of the patch cord plug shown in FIG. 15;

FIG. 17 is a top plan view of the patch cord plug shown in FIG. 15;

FIG. 18 is a section taken substantially along lines 18--18 of FIG. 16;

FIGS. 19 and 19A are interior elevations of the complementary plug bodyhalves shown in FIG. 15;

FIG. 20 is a side elevation showing the profile of one of the contactsprings illustrated in FIG. 3;

FIG. 21 is a fragmentary view of the contact spring as seen from lines21--21 of FIG. 20;

FIG. 22 is a left hand side elevation of a second electrical jackembodiment incorporating additional principles of this invention;

FIG. 22A is a fragmentary enlargement of FIG. 22;

FIG. 23 is a right hand side elevation of the electrical jack shown inFIG. 22;

FIG. 24 is a section taken substantially along lines 24--24 of FIG. 22;

FIG. 25 is a section similar to FIG. 24, but showing a patch cord pluginserted into the uppermost one of the three plug-receiving sockets inthe jack assembly;

FIG. 26 is a section taken substantially along lines 26--26 of FIG. 22;

FIG. 27 is a section similar to FIG. 26, but showing a patch cord pluginserted into the middle or intermediate plug-receiving socket of thejack assembly;

FIG. 28 is a section taken substantially along lines 28--28 of FIG. 22;

FIG. 29 is a section taken substantially along lines 29--29 of FIG. 22;

FIG. 30 is a plan view showing the outer side of one of the contactspring-engaging flaps;

FIG. 31 is a plan view showing the inner side of one of the flaps;

FIG. 32 is a left hand side elevation of the printed circuit board shownin FIG. 22;

FIG. 33 is a right hand side elevation of the printed circuit boardshown in FIG. 22; and

FIGS. 34 and 35 illustrate a schematic circuit diagram of the circuitfor the jack construction shown in FIGS. 22-33.

DETAILED DESCRIPTION

Referring to the drawings, one embodiment of an electrical jack assemblyembodying various principles of this invention is generally indicated at50 in FIGS. 1-6 and is adapted for use with one or more patch cords formaking selected patch field connections. One suitable construction of apatch cord is indicated at 51 in FIG. 1 and is shown to generallycomprise a pair of patch cord plugs or plug connectors 52 and 53 whichare interconnected by a multiple conductor cable 54.

As shown in FIG. 1, jack assembly 50 is advantageously provided with twomulti-terminal connectors 56 and 57 to provide connections to exteriorcircuits or electrical equipment. Each of these connectors is providedwith a multiplicity of mutually insulated terminal pins or elements andmay advantageously be of the standard EIA (Electronic IndustriesAssociation) type. It will be appreciated that any suitable terminalconstruction, design or arrangement may be used in place of connectors56 and 57.

In the use of jack assembly 50, connector 56 is adapted to be connectedby a suitable connector and cable assembly 63 to a selected electricalcircuit A such as a computer and connector 57 is adapted to be connectedby another cable and connector assembly 65 to some other electricalcircuit B such as a data communication terminal or modem.

Referring to FIG. 1A, jack 50 is provided with a multiplicity ofmutually insulated circuits or current conducting paths. These mutuallyinsulated circuits terminate at opposite ends in the terminals ofconnectors 56 and 57 and have normally closed, selectively actutableswitching or contact means for electrically connecting the terminals ofconnector 56 to the terminals of connector 57. In this embodiment theswitching or contact means in the jack assembly comprises two sets ofcontact springs, one set being indicated at 64 and the other set beingindicated at 66.

The contact springs in set 64 cooperate with stationary contacts orelements (to be described later) to establish a first group or array ofnormally closed sets of contacts 67. Similarly, the contact springs inset 66 cooperate with stationary contacts or contact elements (to bedescribed later) to establish a second group or array of normally closedsets of contacts 68. By this arrangement each terminal of connector 56is normally connected by way of two serially connected sets of normallyclosed contacts to a different one of the terminals in connector 57 toestablish the current conducting paths between circuits A and B. Onlythree of these current conducting paths are shown in FIG. 1A to simplifythe schematic diagram of the jack's internal circuitry.

Jack 50 is provided with three plug-receiving sockets 70, 71 and 72, thefirst two of which are used for patch field switching connections, andthe third of which is used for a non-switching monitoring connectionsimilar to the embodiments described in my previously identifiedapplication Ser. No. 650,019. The separate mutually insulated circuitsor circuit connections established between connectors 56 and 57 areconsidered to be normal through or self-normalling circuits in the sensethat contacts 67 and 68 are normally closed to complete or establish thecircuit connections between the terminals of connectors 56 and 57 whenno patch cord plug is received in or patched into either one of both ofthe plug-receiving sockets 70 and 71. Thus, circuits A and B will beelectrically connected by these circuit connections when no patch cordplug is plugged into either one of the sockets 70 and 71.

The contact springs in set 64 are actuated by reception of a patch cordplug in socket 70 to open contacts 67. In a similar fashion the contactsprings in set 66 are actuated by reception of a patch cord plug insocket 71 to open contacts 68. Accordingly, patching a patch cord pluginto either one or both of the plug-receiving sockets 70 or 71 will openthe normal through circuits between connectors 56 and 57, therebyelectrically disconnecting connectors 56 and 57 from each other andhence electrically disconnecting circuits A and B from each other.

Similar to the construction described in my previously identifiedapplication Ser. No. 650,019, up to three of the patch cords 51 may beused with jack 50 to selectively establish various patch fieldconnections. One example of the use of three patch cords is shown inFIG. 1 where the patch cords are respectively indicated at PC-1, PC-2and PC-3. In this example patch cord PC-1 is shown to be plugged into acircuit C, and patch cord PC-2 is shown to be plugged into a circuit D.

Plugging the free plug of patch cord PC-1 into socket 70 electricallydisconnects circuit A from circuit B and completes circuit connectionsfor electrically connecting circuit C to circuit A. Plugging the freeplug on patch cord PC-2 into socket 71 electrically disconnects circuitB from circuit A and completes the circuit connections for electricallyconnecting circuit D to circuit B.

Patching into the monitoring position socket 72 provides monitoring ortrunking connections for picking up the signals or prevailing currentsor voltages at the terminals of connector 57 without opening the normalthrough circuits and also without altering any patch field circuitconnections that may be established by patching into either one or bothof the sockets 70 and 71. Such a monitoring or trunking circuitconnection is established by plugging one of the plugs of patch cordPC-3 into socket 72 and by plugging the other plug of patch cord PC-3into a jack or receptacle 78 which is electrically connected toappropriate monitoring or signal utilization equipment as indicated at80 in FIG. 1. The monitoring equipment may comprise a current meter, avoltage meter, or an oscilloscope.

In addition to connectors 56 and 57 and the contact springs sets 64 and66, the jack assembly shown in FIGS. 2-6 mainly comprises a hollowhousing or body 82 and a printed circuit package 84. Housing 82 ismolded in one-piece from any suitable electrical insulating material andis rectangular in configuration. As shown, housing 82 is open at bothends and is formed with parallel spaced apart top and bottom walls 86and 87 and parallel spaced apart side walls 88 and 89 extending betweentop and bottom walls 86 and 87. The housing openings at the front andback ends are rectangular and aligned.

As shown in FIG. 2, housing 82 is formed with a pair of internal,parallel spaced apart partitioning walls 90 and 91 extending inwardlyfrom the front edge or face of the housing and spanning the space withinhousing 82 between side walls 88 and 89. Partition walls 90 and 91 areintegrally joined to side walls 88 and 89 at right angles thereto andlie parallel with the housing's top and bottom walls 86 and 87. Walls 90and 91 divide the open front end of housing 82 into three equallydimensioned segments to define or form the plug-receiving sockets 70-72in jack assembly 50.

More specifically, socket 70 is formed and delimited by top wall 86,partition wall 90 and the portions of side walls 88 and 89 extendingbetween walls 86 and 90, socket 71 is formed and delimited by partitionwalls 90 and 91 and the portions of side walls 88 and 89 extendingbetween the partition walls 90 and 91, and socket 72 is formed anddelimited by partition wall 91 and bottom wall 87 and the housing's sidewall portions extending between walls 91 and 87. By this construction itwill be appreciated that sockets 70-72 open at the front end of housing82, are equally dimensioned, are coextensive and open at their rearwardends into the hollow interior of housing 82.

Sockets 70-72 lie in a straight row between the housing's top and bottomwalls and are each constructed to accept or slidably receive the sametype of patch cord plug. In this embodiment it will be noted thatsockets 70-72 are rectangular in configuration rather than being roundas is the case with the electrical jacks described in my previouslyidentified application Ser. No. 650,019.

Referring to FIGS. 3, 4, 13 and 14, the printed circuit package 84includes a printed circuit board 94 having a first printed circuitpattern 96 suitably formed or imposed on one side thereof and a secondprinted circuit patten 98 suitably imposed on the opposite side thereof.In addition to the printed circuit board 94, the printed circuit packagealso includes a pair of rider board assemblies 99 and 100 mounted onopposite sides of the printed circuit board 94. Although both sides ofthe printed circuit board 94 are used in this embodiment forestablishing the various circuit connections in the jack assembly itwill be appreciated that the various principles of this invention may beutilized in an electrical jack construction in which only one side ofthe printed circuit board is used, and not the other.

The printed circuit board 94 may be formed from any suitably electricalinsulating material and extends into the interior of housing 82 throughthe rearward open end of the housing to lie parallel to and midwaybetween the housing side walls 88 and 89. The upper and lower edges ofprinted circuit board 94 are slideably received in opposed inwardlyopening flat-bottomed guide channels or grooves 102 and 104. Grooves 102and 104 are formed in the interior faces of the top and bottom walls 86and 97, respectively.

As shown, board 94 projects rearwardly from housing 82 such that itsrearward end is exterior of the housing. Connectors 56 and 57 areadvantageously detachably mounted by screws 105 on the rearward endportion of board 94 exteriorly of housing 82.

To guide and confine the printed circuit board 94, housing 82 isintegrally formed with interior stiffening ribs 106, 107, 108, 109, 110and 111. Ribs 106-108 are integral with and extend inwardly from sidewall 88 and ribs 109-111 are integral with and extend inwardly from sidewall 89 in such a manner that ribs 109-111 align with ribs 106-108respectively. The end faces of ribs 106-108 are spaced equidistantlyapart from the opposing end faces of ribs 109-111. The printed circuitboard 94 is slideably received between the one set of ribs 106-108 andthe other set of ribs 109-111 as shown.

Printed circuit board 94 is rigidly but detachably secured to housing 82by just two fastener assemblies 114 and 116, each consisting of a screwand nut. The screw of fastener assembly 114 extends through a bore orhole 118 which is formed through side wall 88, ribs 106 and 109 and sidewall 89. The screw of fastener assembly 116 extends through another boreor hole 120 which is formed through side wall 88, ribs 107 and 110 andside wall 89. The axes of holes 118 and 120 are in parallel spaced apartrelation and extend normal to side walls 88 and 89.

The side walls 88 and 89 of housing 82 are sufficiently flexible todeflect slightly when the nuts of fastener assemblies 114 and 116 aretightened to securely clamp the printed circuit board 94 in place inhousing 82 between the two opposing sets of ribs in the housing.Fastener assemblies 114 and 116 are the only mechanical fasteners thatare used in the complete jack assembly apart from those that areemployed to detachably mount connectors 56 and 57 on the printed circuitboard. This construction simplifies and reduces the expense ofassembling the component parts of jack assembly 50.

As shown in FIGS. 5, 7 and 9, jack assembly 50 may be provided with aback cover plate 119 for housing 82. Plate 119 is molded from anysuitable electrical insulating material and is snugly received with atight fit between side walls 88 and 89 to seat against the rearwardedges of walls 86 and 87. Plate 118 closes or covers the open rear endof housing 82 and is formed with a longitudinal slot 121 through whichthe printed circuit board 94 extends. Preferably, plate 119 is fixed tothe rearward end of housing 82 by adhesive or bonding. By thisconstruction plate 119 is mounted in place on housing 82 without the useof mechanical fasteners of any kind.

As shown in FIGS. 13 and 14, the forward edge of printed circuit board94 in housing 82 is notched to form two forwardly opening slots 122 and124 for receiving the rearward end portions of partition walls 90 and91, respectively. Slots 122 and 124 divide the forward edge portion ofprinted circuit board 94 into three forwardly extending segments 126,127 and 128. Segments 126-128 project forwardly into sockets 70-72,respectively, and lie in a common plane that medially intersects housing82 and sockets 70-72 in parallel relation to the housing side walls 88and 89.

Patch cord plugs 52 or 53 are of the same construction as shown in FIGS.15-17. Each of these plugs is of the edge connector type having a hollowinsulating body 130, a first set of contact spring elements 134, and asecond set of contact spring elements 136. As shown, body 130 is formedwith an open, rectangular circuit board-receiving end 137. Contactelements 134 and 136 are mounted in body 132 and are arranged in twoparallel spaced apart rows to define an outwardly opening mouth forreceiving any one of the printed circuit board segments 126-128depending upon which one of the jack assembly sockets the plug isplugged into. It will be appreciated that the plug and electrical jackconstruction is such that either one of the plugs 52 or 53 is pluggableinto any selected one of the jack sockets 70-72.

In each patch cord plug, the contact elements are mutually insulatedfrom each other. The contact elements in plug 52 are individuallyconnected by separate conductors in cable 54 to corresponding contactelements in plug 53, whereby separate mutually insulated currentconducting paths are established between the corresponding contactelements in the two plugs.

To make circuit contact with the contact spring elements 134 in eitherone of the patch cord plugs 52 or 53, the printed circuit pattern 96 onone side of the printed circuit board 94 includes finger stock (see FIG.13) comprising a first set of contact fingers 138, a second set ofcontact fingers 139, and a third set of contact fingers 140. Fingers138-140 are coextensively arranged in parallel spaced apart relation ina straight row and extend rearwardly from the forward edge of printedcircuit board 94. As shown, fingers 138 are formed on the printedcircuit board segment 126, fingers 139 are formed on the printed circuitboard segment 127, and fingers 140 are formed on the printed circuitboard segment 128.

Where it is desired to utilize both sides of the printed circuit board94 and all of the contact spring elements in each of the patch cordplugs, the printed circuit pattern 98 on the right hand side of printedcircuit board 94 also includes finger stock corresponding to the fingerstock just described for the left hand side of printed circuit board 94.More specifically, the printed circuit finger stock on the right handside of printed circuit board 94 comprises a first set of contactfingers 141 corresponding to fingers 138, a second set of contactfingers 142 corresponding to fingers 139 and a third set of contactfingers 143 corresponding to fingers 140 as shown in FIGS. 1B and 14.

Fingers 141-143 are coextensively arranged in a straight row and extendrearwardly from the forward edge of printed circuit board 94. Similar tothe arrangement of fingers 138-140, fingers 141 are disposed on theprinted circuit board segment 126, fingers 142 are disposed on theprinted circuit board segment 127 and fingers 143 are disposed on theprinted circuit board segment 128.

In utilizing both sides of the printed circuit board 94 the terminals inconnector 56 may be divided into a first set indicated at 146 and asecond set indicated at 147. Similarly, the terminals in connector 57may be divided into a first set indicated at 148 and a second setindicated at 149.

Each of the fingers 138 is connected by a separate printed circuitconductor or track 152 (FIG. 1A) to a different one of the connectorterminals 146, and each of the fingers 141 on the opposite side of theprinted circuit board is connected by a separate printed circuitconductor or track 155 (FIG. 1B) to a different one of the connectorterminals 147. In a similar fashion each of the fingers 139 is connectedby a separate printed circuit conductor or track 153 (FIG. 1A) to adifferent one of the connector terminals 148, and each of the fingers142 is connected by a separate printed circuit conductor or track 156(FIG. 1B) to a different one of the connector terminals 149.

In this embodiment each of the fingers 140 is connected by a separateprinted circuit conductor or track 154 (FIG. 1A) to a different one ofthe connector terminals 148, and each of the fingers 143 is connected bya separate printed circuit conductor or track 157 (FIG. 1B) to adifferent one of the connector terminals 149.

To establish the current conducting paths between fingers 140 andconductor terminals 148 with minimal use of printed circuit conductors,each of the printed circuit conductors 154 may be joined to a differentone of the printed circuit conductors 153. Likewise each of the printedcircuit conductors 157 may be joined to some point on a different one ofthe printed circuit conductors 156 (FIG. 1B) to reduce the extent ofprinted circuit tracks in the patterns on the printed circuit board.

Depending upon the printed circuit conductor pattern used, each of theprinted circuit conductors 152-157 may be divided into differentsegments, some extending on one side of board 94 and others extending onthe other side of board 94 to avoid interference between the variousconductors in the printed circuitry.

It will be appreciated that any suitable pattern or arrangement of theprinted circuit conductors 152-157 may be utilized in conjunction withthe principles of this invention, the one shown in the drawings beingmerely illustrative.

From the foregoing description it will be appreciated that insertion ofeither one of patch cord plugs 52 or 53 into socket 70 in the mannershown in FIG. 8 results in the electrical contact of each of the plug'scontact elements 134 with a different one of the fingers 138 to therebyprovide for the electrical connection of each of the contact elements134 to a different one of the connector terminals 146. Insertion ofeither of the plugs 52 or 53 into socket 70 also results in theelectrical contact of each of the plugs's contact elements 136 with adifferent one of the fingers 141, thereby electrically connecting eachof the contact elements 136 to a different one of the connectorterminals 147.

Insertion of either of the patch cord plugs 52 or 53 into socket 71 inthe manner shown in FIG. 10 similarly results in the electrical contactof each of the plug contact elements 134 with a different one of thefingers 139 to thereby electrically connect each of the plug's contactelements 134 to a different one of the contact terminals 148. Insertionof either one of the plugs 52 or 53 into socket 71 also results in theelectrical contact of each of the plug's contact elements 136 with adifferent one of the fingers 142, thereby electrically connecting eachof the contact elements 136 to a different one of the connectorterminals 149.

Insertion of either one of the plugs 52 or 53 into socket 72 in themanner shown in FIG. 11 results in the electrical contact of each of theplug's contact elements 134 with a different one of the fingers 140 andalso each of the plug's contact elements 136 with a different one of thefingers 143. As a result, each of the plug's contact elements 134 willbe electrically connected to a different one of the connector terminals148 and each of the plug's contact elements 136 will be electricallyconnected to a different one of the connector terminals 149.

In this embodiment the contact spring set 64 includes a first group ofcontact springs 160 and a second group of contact springs 162. As shownin FIGS. 7 and 8 these two groups of contact springs are disposed onopposite sides of the printed circuit board 94 for operation with socket70. In a similar manner the contact spring set 66 includes a first groupof contact springs 161 and a second group of contact springs 163respectively disposed on opposite sides of printed circuit board 94 foroperation with socket 71.

On one side of the printed circuit board 94 the printed circuit patternis formed with a first set or group of contact pads or strips 166 forcontact springs 160 and a second set or group of contact pads or strips167 for contact springs 161. In addition to contact pads 166 and 167,contact pads are formed on a printed circuit rider board 170 which formsa part of the rider board assembly 99. More specifically, the printedcircuit on rider board 170 includes a first set or group of contact pads172 for contact springs 160 and a second set or group of contact pads173 for contact springs 161.

In addition to board 170, the rider board assembly 99 also includes aninsulating board 176. Insulating board 176 is bonded or otherwiserigidly attached on one side to printed circuit board 94. Board 170 isbonded to or otherwise rigidly attached to the other side of insulatingboard 176 such that insulating board 176 lies between the main printedcircuit board 94 and rider board 170 to electrically insulate theprinted circuit pattern on rider board 170 from the printed circuitrythat is applied directly to the printed circuit board 94.

The printed circuit pads 166 and 167 are in parallel spaced apartrelationship and are arranged in a straight row along an intermediateportion of board 94 between the row of fingers 138 and 139 and theterminals for connectors 56 and 57. Rider board assembly 99 is disposedbetween the row of contact pads 166 and 167 and the row of fingers 138and 139. Contact pads 172 and 173 are disposed in parallel spaced apartrelation and are arranged in a straight row which lies between the rowof fingers 138 and 139 and the row of contact pads 166 and 167.

As shown in FIGS. 1A and FIG. 13, each of the contact pads 166 forms apart of a different one of the printed circuit conductors 152, and eachof the contact pads 167 forms a part of a different one of the printedcircuit conductors 153.

Each of the contact springs 160-163 has a tail 180 and a deflectiblecircuit breaking end 182. The tail 180 of each contact spring 160stationarily seats against and makes electrical contact with a differentone of the contact pads 166. Similarly, the tail 180 of each contactspring 161 stationarily seats against and makes electrical contact witha different one of the contact pads 167.

The deflectible circuit-breaking end 182 of each contact spring 160 isnormally biased to seat against and make electrical contact with adifferent one of the contact pads 172 on rider board 170. Thedeflectible ends of springs 160 and contact pads 172 define the normallyclosed sets of contacts 67. Each contact spring 160 is thereforearranged and normally biased to contact a different one of the contactpads 166 and a different one of the contact pads 172 to establish abreakable circuit connection therebetween.

The deflectible end 182 of each contact spring 161 is normally biased toseat against and thus make electrical contact with a different one ofthe contact pads 173 on rider board 170 to thus define the normallyclosed sets of contacts 68. Each contact spring 161 is thereforearranged and normally biased to contact a different one of the contactpads 167 and a different one of the contact pads 173 to establish abreakable circuit connection therebetween.

The printed circuit pattern on rider board 170 also includes amultiplicity of printed circuit conductors or tracks 186. Each of thecontact pads 172 is connected by a different one of the printed circuitconductors 186 to a different one of the contact pads 173. Contactsprings 160 will be in electrical contact with contact pads 172 when nopatch cord plug is inserted into socket 70, and contact springs 161 willbe in electrical contact with contact pads 173 when no patch cord plugis inserted into socket 71.

From the foregoing description it will be appreciated that the circuitdesign including conductors 152, contact pads 166, contact springs 160,contact pads 172, the rider board printed circuit conductors 186,contact pads 173, contact springs 161, contact pads 167 and the printedcircuit conductors 153 establishes a multiplicity of mutually insulatedcurrent conducting paths or circuits each having two serially connectedsets of contacts 67 and 68. Each of the connector terminals 146 isconnected by a different one of these current conducting circuits to adifferent one of the connector terminals 148. Furthermore, each of thesecurrent conducting circuits may be traced from one of the connectorterminals 146 through one of the printed circuit conductors 152, throughone of the contact pads 166, through one of the contact springs 160,through one of the contact pads 172, through one of the printed circuitconductors 186, through one of the contact pads 173, through one of thecontact springs 161, through one of the contact pads 167, and throughone of the printed circuit conductors 153 to one of the connectorterminals 148.

The rider board assembly 100 on the right hand side of printed circuitboard 94 is the same as rider assembly 99 on the opposite side of theprinted circuit board. Accordingly, like reference numerals have beenapplied to designate like components of the two rider boards except thatthe reference numerals applied to the component parts of the rider boardassembly 100 have been suffixed by the letter "a" to distinguish themfrom the reference numerals used for the component parts of rider board99.

In addition to the rider board contact pads 172a and 173a the printedcircuit pattern on the right hand side of printed circuit board 94 isformed with two sets of contact pads 166a and 167a as shown, forexample, in FIG. 1B. Pads 166a and 167a correspond respectively to thepads 166 and 167. The arrangement of the contact pads 166a and 167a andfingers 141 and 142 along with the rider board contact pads 172a and173a is the same as the arrangement described above for contact pads166, 167, 172 and 173 and fingers 138 and 139. Additionally, theconstruction and arrangement of contact springs 162 and 163 correspondto that just described for contact springs 160 and 161 on the oppositeside of the printed circuit board 94.

The tail of each contact spring 162 seats against and makes electricalcontact with a different one of the contact pads 166a as best shown inFIGS. 7 and 9. Similarly, the tail of each of contact springs 163 seatsagainst and makes electrical contact with a different one of the contactpads 167a.

The deflectible end of each of the contact springs 162 is normallybiased to seat against and make electrical contact with a different oneof the rider board contact pads 172a in such a manner that each pair ofthe engaging deflectible contact spring ends and rider board contactpads defines a set of normally closed contacts corresponding to contacts67.

In a similar manner the deflectible end of each of the contact springs163 is normally biased to seat against and make electrical contact witha different one of the rider board contact pads 173a in such a mannerthat each interengaging pair of the contact spring ends and rider boardcontact pads defines a set of normally closed contacts corresponding tothe previously described normally closed contacts 68.

Similar to the circuit connections established by contact springs 160and 161, contact springs 162 will be in electrical contact with contactpads 172a when no patch cord plug is inserted into socket 70, andcontact springs 163 will be in electrical contact with contact pads 173awhen no patch cord plug is inserted into socket 71. As shown, each ofthe contact pads 166a forms a part of a different one of the printedcircuit tracks 155, and each of the contact pads 167a forms a part of adifferent one of the printed circuit tracks 156.

From the foregoing description it will be appreciated that the circuitdesign including conductors 155, contact pads 166a, contact springs 162,contact pads 172a, the rider board printed circuit conductors 186a,contact pads 173a, contact springs 163, contact pads 167a, and theprinted circuit conductors 156 establishes a multiplicity of mutuallyinsulated current conducting paths or circuits each having two sets ofserially connected normally closed contacts. Each of the connectorterminals 147 is connected by a different one of these currentconducting circuits to a different one of the connector terminals 149.

As will be described in greater detail below springs 160 and 162 arearranged in housing 82 in such a way that they are engaged by either oneof the patch cord plugs 52 or 53 upon insertion thereof into socket 70to lift their deflectible ends 182 off the rider board contact pads 172and 172a, thereby opening or breaking the normal through circuitconnections between connectors 56 and 57 and thus electricallydisconnecting the terminals of connector 56 from the terminals ofconnector 57. Insertion of the plug in socket 70 also establishespreviously described circuit connections between the patch cord plugcontact elements 134 and 136 and the terminals of connector 56 by way ofthe fingers stock and printed circuit conductors on the printed circuitboard 94.

In a similar fashion contact springs 161 and 163 are arranged in such away on housing 82 to be engaged by either one of the patch cord plugs 52or 53 upon insertion thereof into socket 71 to lift the deflectible endsof springs 161 and 163 off their associated contact pads 173 and 173a,thereby opening or breaking the circuit connection between connectors 56and 57 and thus electrically disconnecting the terminals of connectors56 from the terminals of connectors 57. Insertion of plug in socket 71additionally establishes the previously described electrical circuitconnections between the patch cord plugs's contact elements 134 and 136and the terminals of connector 57 by way of the finger stock and printedcircuit conductors on the printed circuit board 94.

As shown in FIGS. 7, 8 and 20, each of the contact springs 160 is ofidentical construction and may be formed from any suitable flat-sidedspring metal material. Each of the springs 160 is bent back towardsitself to form two separate spring arms or portions 190 and 191 whichare integrally joined together by a curved intermediate nose portion192. Spring arm 190 terminates in the free contact-engaging end 180, andspring arm 191 terminates in the other contact-engaging end 182. In theassembled relation of parts spring arm 191 lies between spring arm 190and printed circuit board 94, and the free ends 180 and 182 are spacedapart as shown.

Spring arm 190 is somewhat longer than spring arm 191 to extend beyondthe free end of arm 191. In FIG. 20, spring 160 is shown in its relaxed,undeflected, unflexed condition.

Still referring to FIG. 20, spring 160 is formed with three spaced apartstraight segments 194, 195 and 196 and three sharply bent, crooked oroffset portions 197, 198 and 199. The straight spring segment 194extends between the intermediate spring portion 192 and offset portion197. Offset portion 197 interconnects and provides an offsettingtransition between the straight spring segments 194 and 195. The offsetportion 198 interconnects and provides an offsetting transition betweenthe straight spring segments 195 and 196, and offset portion 199interconnects and provides an offsetting transition between the springsegment 196 and the contact-engaging straight end 180. The transitionsprovided by offset portions 197-199 step spring arm 190 in a commondirection toward spring arm 191 in the manner shown.

Spring arm 191 is formed with two essentially straight segments 200 and201 and a sharply bent, crooked or offset transition 202 betweensegments 200 and 201 to step arm 191 toward arm 190. Spring segment 200lies between nose portion 192 and transition 202, and spring segment 201lies between transition 202 and the contact pad-engaging end 182 whichis rounded or curved as shown. Each of the contact-engaging ends 180 and182 is preferably bifurcated to provide two coextensive independentlydeflectible leg portions as shown in FIG. 19A.

Springs 161-163 are of the same construction as that just described forspring 160. Accordingly, like reference numerals have been applied todesignate like portions of springs 160-163.

As shown in FIGS. 3 and 4, jack housing 82 is provided with four equallysized rectangular windows or apertures 210, 211, 212 and 213 forreceiving springs 160, 161, 162 and 163, respectively. Windows 210 and211 are formed through side wall 89 and are arranged in aligned relationin such a manner that window 210 opens into socket 70 and window 211opens into socket 71.

Windows 212 and 213 are on the opposite side of housing 82 from windows210 and 211 and are formed through side wall 88 at locations wherewindow 212 registers with window 210 and opens into socket 70 and window213 registers with window 211 and opens into socket 71.

The axis of each plug-receiving socket 70-72 may be assumed to be at themidpoint of the socket equidistant from the corners of the socket. Theseplug-receiving socket axes are in parallel spaced apart relation and arecontained in a common plane extending parallel to the jack housing sidewalls 88 and 89 and medially intersecting circuit board 94 in parallelrelation to the print circuit board's circuit bearing side faces. Aswill be described in greater detail below the arrangement of springs160-163 is symmetrical with respect to this plane.

As shown in FIGS. 3, 7 and 8, housing 82 is integrally formed with acontact spring support shelf or ledge 216 extending along and recessedor offset inwardly from the forward edge surface 214 of window 210 whichis closest to the front face of housing 82.

The nose portions 192 of springs 160 are received on shelf 216. By thisarrangement the ends of spring arms 191 that merge with nose 192 seat onshelf 216.

As shown, springs 160 extend in parallel spaced part relationshiprearwardly from the forward window edge 214 and shelf 216. Springs 160are maintained in this non-contacting parallel spaced apart relationshipby a first set of spacer ribs 218, a second set of spacer ribs 219 and athird set of spacer ribs 220. Ribs 218 extend rearwardly from windowedge 214 in parallel spaced apart relation along shelf 216. The noseportions 192 of springs 160 lie between ribs 218 as shown.

Ribs 219 are also integrally formed on housing 82 on the interior sideof side wall 89 and extend rearwardly from the rear edge of window 210as best shown in FIG. 7. Ribs 220 extend along a shallow channel 222which is formed in back plate 119 and which opens into the back plateslot 121.

Referring to FIGS. 3, 7 and 12 the spring arm segment 194 of each of thesprings traverses window 210 and 160 extends in a plane that isapproximately level with the outer surface of side wall 89 to a pointjust forwardly of the rearward edge surface 224 of window 210. Theoffset portions 197 of springs 160 pass through window 210 into theinterior of housing 82 in such a manner that spring segments 196 liewithin housing 82 and extend rearwardly with respect to window 210 whilethe spring segments 190 lie in registry with window 210 and are thusexposed for access on the exterior of jack assembly 50. As shown, springsegments 195 lie between and are thus spaced apart by ribs 219.

The transition spring portions 199 offset the contact-engaging ends 180inwardly toward the printed circuit board 94 and away from the jackhousing side wall 89. The end portions 180 of springs 160 extend throughthe open ended grooves defined by ribs 220 to lie between ribs 220 incontact with the contact pads 166.

As shown in FIG. 7, the inner sharp housing corner defined by therearward window edge surface 224 seats against the corner juncture 226that is defined between the transition spring portion 119 and the springsegment 195 in each of the contact springs 160 to flex or deflect eachcontact spring arm 190 inwardly toward circuit board 94, whereby theflat contact-engaging end 180 of each spring arm 190 is yieldably biasedinto contact with its associated contact pad 166 on the printed circuitboard. As is apparent from the above, the biasing or flexing forceexerted by the housing window edge 224 on each contact spring arm 190 isat a point intermediate the opposite ends of the contact spring arm 190.

Still referring to FIG. 7, it will be noted that the contact spring ends180 extend beyond back plate 119 such that back plate 119 traps thespring ends 180 in the grooves defined by ribs 220.

From its end position on shelf 216 contact spring arm 191 of each spring160 passes through window 210 and socket 70 to a position where itscontact-engaging end 182 seats on its contact pad 166 rearwardly ofsocket 70. It will be noted that rider boards 170 and 170a are disposedwithin housing 82 rearwardly of sockets 70-72.

As shown in FIG. 7, only two points of contact or engagement areestablished between each of the spring arms 191 and the remainder of thejack assembly 50. One of these points is the seating engagement of theforward end of each spring arm 191 or shelf 216. The other point of theengagement is at the curved contact-engaging end 182 where thecontact-engaging end seats against its associated contact pad 172 on therider board 170 within housing 82. Between these two points ofengagement each spring arm 191 is free to flex or bow in eitherdirection, that is either towards board 94 or away from board 94. Thedistance between shelf 216 and the plane containing the rider boardcontact pads 172 is smaller than the corresponding projected dimensionbetween the opposite ends of each contact spring arm 191 in its relaxed,unflexed condition. Because of this arrangement and because of the twopoint spring arm engagement described above, the intermediate portion ofspring arm 192 lying between end 182 and the other end at nose portion192 to flex or bow slightly inwardly away from spring arm 190 andtowards the printed circuit board 94.

As either one of the patch cord plugs 52 or 53 is inserted into theplug-receiving socket to receive the printed circuit board edge segment126, the forward, outer corner edge 228 of the plug's rectangularinsulating body 130 engages and slides along the segments 200 of springarms 191, causing the spring arms 191 to flex in the direction oppositeto the bow or flexure in FIG. 7, causing the intermediate portions ofspring arms 191 to give or flex first before the contact spring ends 182lift off their respective contact pads 172. This results in a wipingaction as will be explained in detail below. As the inward pluggingmotion of the patch cord plug continues the forward plug body edge 228travels along the segments 200 of the spring arms 191 to impart alifting motion to spring arms 191, thereby causing the spring arms ends182 to lift away from their contact pads 172. Lifting the contact springends 182 in this manner electrically disconnects the contact springs 160from contact pads 172. As shown, each spring arm 191 flexes at theregion where it joins to nose portion 192 as it is lifted away fromboard 94 by the patch cord plug.

Since spring arms 191 are normally flexed towards printed circuit board94 when no patch cord plug is received in socket 70 and since theintermediate portions of spring arms 191 are flexed by the patch cordplug before their contact-engaging ends 182 lift off their associatedcontact pads the contact-engaging ends 182 will slide forwardly slightlyon their respective contact pads 172 before lifting off to wipe andthereby clean the pads in the process of lifting the contact spring armsaway from the contact pads. As the patch cord plug is partially removedfrom socket 70 the contact spring ends 182 will initially touch down ontheir respective contact pads 172 and then as the patch cord plug iswithdrawn to a further extent, the bow or flexure of the contact springarms 191 will increase in deflection towards the printed circuit board.This causes the contact spring ends 182 to slide rearwardly on thecontact pads 172, whereby further wiping action is achieved to clean thecontact pads. Accordingly, insertion and removal of either one of thepatch cord plugs 52 or 53 has the effect of causing the contact springarms 191 to wipe their respective contact pads 172.

Ribs 220 confine the contact spring ends 180 against lateral movement.Engagement of the window edge 224 with the corners 226 on spring arms190 limits rearward movement of the contact springs and prevents outwardmovement of the contact springs 160 through window 210, therebypreventing the springs from popping out through the window. Seatingengagement of the nose portions 192 on shelf 216 prevents inwardmovement of the contact springs 160. The window edge surface 214 limitsforward movement of the contact springs 160 towards the front of housing82.

Rather than being affixed by any means such as fasteners or solderingconnections it will be appreciated from the foregoing description thatcontact springs 160 are trapped or confined in place in separableseating surface engagement with the various portions of housing 82 andprinted circuit board 94 mentioned above. This unique arrangementsimplifies the jack construction, avoids the need for extra fasteners orsoldering connections for mounting the contact springs in place andadditionally simplifies the assembly and removal of the contact springs.

For example, any one of the contact springs 160 is easily removablesimply by first lifting and raising its nose portion 192 out of window210 to clear the adjacent window edge 214 and then by pulling thecontact spring forwardly to slide it out of the housing by way of window210. Insertion of the contact spring 160 into its operating position inhousing 82 is accomplished by simply reversing the process mentionedabove.

Because of the foregoing arrangement and construction described abovethe overall assembly of the component jack parts is also simplified aswill be described in greater detail later on.

Ribs 218-220 function to properly align contact springs 160 with theirrespective contact pads 166 and 172. Ribs 219 and 220 additionallyfunction to guide the contact springs as they are inserted into housing82 through window 210.

It will be noted that for each contact spring 160 the flexure ordeflection of spring arm 191 does not result in flexure or deflection ofspring arm 191. The two spring arms therefore act independently of eachother.

Spacer ribs, spring-supporting window shelves and back plate channelscorresponding to ribs 218-220, shelf 216 and channel 272 are providedfor each of the three remaining sets of contact springs 161-163 and areof the same construction as the rib, window shelf and back plate channelconstruction just described for contact springs 160.

Accordingly, like reference numerals have been applied to designate likeribs, support shelves and back plate channels for the springs 160-163except that (a) the reference numerals applied to the ribs, shelf andchannel for contact springs 161 have been suffixed by the letter a, (b)the reference numerals applied to the spacer ribs, support shelf andchannel for contact springs 162 have been suffixed by the letter b, and(c) the reference numerals applied to the spacer ribs, support shelf andchannel for contact springs 163 have been suffixed by the letter c tothereby distinguish the various groups of reference numerals from eachother.

The configurations of windows 210-213 are also the same. Accordingly,like reference numerals have been applied to designate the front andrear edges for the four windows except that the reference numeralsapplied to designate the window edges for window 211 have been suffixedby the letter a, the reference numerals applied to the edges of window212 have been suffixed by the letter b, and the reference numeralsapplied to the edges of window 213 have been suffixed by the letter c.

Springs 161 are maintained in parallel spaced apart relation and inproper alignment with their associated contact pads 167 and 173 by ribs218a, 219a and 220a in the same manner just described for springs 160.Similarly, springs 162 are maintained in parallel spaced apart relationand in proper alignment with their associated contact pads 166a and 172aby ribs 218b, 219b and 220b in the same manner previously described forsprings 160. Likewise, springs 163 are maintained in parallel spacedapart relation and in proper alignment with their associated contactpads 167a and 173a by ribs 218c, 219c and 220c in the same mannerdescribed above for springs 160.

Springs 161-163 are arranged and assembled in the same manner describedabove for contact springs 160. In particular, springs 161 are receivedin window 211, springs 162 are received in window 212 and springs 163are received in window 213.

Being constructed and arranged in the same way as springs 160, thecontact spring arms 190 and 191 for springs 161-163 will be biased anddeflected in the same manner just described for springs 160.Furthermore, upon insertion of a patch cord plug into socket 70 thespring arms 191 of springs 162 will be lifted to their circuit-breakingpositions concomitantly with the spring arms 191 of springs 160 and inthe same manner just described for springs 160. Upon insertion of apatch cord plug into socket 71, the spring arms 191 of springs 161 and163 will be lifted concomitantly to their circuit-breaking positions inthe manner described above for springs 160.

Since springs 161-163 are of the same constructions as springs 160 andsince springs 161-163 are arranged and assembled in housing 82 in thesame manner previously described for springs 160 it will be appreciatedthat the same contact pad-wiping action previously described for springs160 is also accomplished with springs 161-163.

As shown in FIG. 7, springs 160 and 162 are symmetrically arranged abouta plane medially intersecting sockets 70-72 and effectively containingthe printed circuit board 94. By this arrangement the spring arms 191 ofcontact springs 160 and the spring arms 191 of contact springs 162converge towards each other in a direction extending towards the rearplate 119 to thereby define an outwardly diverging mouth for receivingthe forward nose of the patch cord plug body 130 as the plug is insertedinto socket 70. Springs 161 and 163 are symmetrically arranged in thesame manner in socket 71.

By virtue of the foregoing symmetrical relationship of springs 160 and162 in socket 70 it will be appreciated that as either one of the patchcord plugs 52 or 53 is inserted into socket 70 the forward corners 228and 229 on plug body 130 will concomitantly engage the spring arms 191on the opposite sides of printed circuit board 94 and thus will travelalong the portions of spring arms 191 of springs 160 and 162 in socket70 to concomitantly lift the spring arms 191 of springs 160 and 162 awayfrom their respective contact pads on the rider board.

Continued inward motion of the patch cord plug body 130 results in theengagement of the forward end of the plug body 130 with the offsetspring portions 202 of springs 160 imparting a camming action theretoand causing the corners 230 of these offset portions 202 to ride overthe plug body 130 along its outer side face 232 to a position where itregisters with a shallow, outwardly-opening, straight flat-bottomedchannel or groove 234 which is formed in the outer side face 232 andwhich extends normal to the contact spring arms 191.

At the same time that the plug body 130 engages the offset springportions 202 of springs 160, it will also engage the offset springportions 202 of springs 162, thereby imparting a camming action theretoand causing the corners 230 of springs 162 to ride over the plug body130 along its other side face 233 to a position where they register withanother outwardly opening shallow, flat-bottomed channel or groove 235which is formed in side face 233 and which corresponds to groove 234.

Thus, upon fully inserting the patch cord plug into socket 70 to itsoperative circuit-making and circuit-breaking position, the self bias ofthe spring arms 191 on springs 160 will yieldably urge their corners 230to seat in the plug body groove 234. At the same time the self bias ofthe spring arms 191 on springs 162 will yieldably urge their corners 230to seat in the plug body groove 235 on the opposite side of the plugbody. Seating the spring arm corners 230 in the plug body grooves 234and 235 on opposite sides of the plug body yieldably and releaseablylocks the patch cord in its inserted, operating position in theplug-receiving socket. It therefore will be appreciated that coactingmeans in the form of the contact spring corners 230 and the plug bodygrooves 234 and 235 establish a releaseable detent-like lock or latchfor releaseably retaining the path cord plug in its fully insertedposition in socket 70.

Exertion of an outward force on the inserted patch cord plug to removeit from socket 70 causes the corners 230 of springs 160 and 162 to camover the edges of their associated plug body grooves 234 and 235, thusyieldably flexing the arms 191 of springs 160 and 162 to release thepatch cord plug for removal from the jack's plug-receiving socket 70.Upon removal of the patch cord plug from socket 70 the arms 191 ofsprings 160 and 162 will bow or flex inwardly again toward the printedcircuit board 94 again, causing the contact ends 182 to touch down ontheir respective contact pads.

Assembly of the printed circuit board 94 and contact springs 160-163with housing 82 is accomplished by first positioning back plate 119 inplace on the open back of housing 82 and then by slidably inserting theprinted circuit board 94 through slot 121 and into housing 82.Thereafter, fasteners 114 and 116 are inserted to fix the printedcircuit board 94 to housing 82. After this is done contact springs 160are assembled with the jack housing and printed circuit board simply byslidably inserting them through window 160 to their operating positionsshown in the drawings. Springs 161-163 are assembled in the same mannerdescribed above for springs 160 to complete the assembly of thecomponent jack parts.

As best shown in FIG. 10, contact springs 161 and 163 also establish areleaseable lock with either one of the patch cord plugs 52 or 53 uponinsertion thereof into socket 71 in the same manner just described forcontact springs 160 and 162.

As shown in FIG. 8 the forwardly facing edge surfaces of spacer ribs219, 219a, 219b and 219c lie in a common plane normally intersecting thelongitudinal axes of the plug-receiving sockets 70 and 71. The forwardlyfacing edge surfaces of ribs 219 and 219a are indicated at 237 and limitthe inward movement of either of the patch cord plugs 52 or 53 intosocket 70 to thereby define the rearward end of socket 70.

As shown in FIG. 10, the forwardly facing edge surfaces of ribs 219b and219c are indicated at 239 and similarly limit the inward movement ofeither one of the patch cord plugs 52 or 53 into socket 71 to therebydefine the rearward end of socket 71.

It will be appreciated that a unitary multi-layer printed circuit boardhaving alternate layers of insulating material and printed circuitry maybe used in place of the rider board assemblies 99 and 100 and printedcircuit board 94 to provide the previously described printed circuitpatterns.

It will be noted that in practice some of the segments of the riderboard conductors 186 extend along the underside of board 170 to avoidinterference between the printed circuitry on the rider board. The sameapplies to the conductors or rider board 170a.

From the foregoing description it also will be appreciated that theelectrical jack of this invention has relatively few parts, it compactlyand efficiently organized to define a relatively small overall package,is inexpensive to manufacture and easy to assemble, and assures positiveand reliable circuit-making and circuit-breaking operations uponinsertion of a patch cord plug into any one or more of the three patchcord plug-receiving sockets. Additionally, it will be noted that variousfeatures of this invention may be used with either one or both of thepatch cord plug-receiving sockets 70 and 71 apart from the non-switchingmonitoring socket 72.

As compared with the first jack construction embodiment just described,the embodiment shown in FIGS. 22-23 is modified to eliminate the riderboard assemblies 99 and 100 and to reduce the number of contact springsin each of the four sets of springs 160-163 by one half without reducingthe number of normal through circuits or current conducting pathsthrough the jack assembly. This is mainly accomplished by providing thesecond embodiment with a pair of pivotal one-piece flaps 250 and 252 andby modifying the printed circuits on both sides of the printed circuitboard 94 in a manner to be described in detail below. For the most partthe jack construction shown in FIGS. 22-35 is otherwise the same as thejack construction illustrated in FIGS. 2-4. Like reference numerals havetherefore been used to designate like parts or components of the twojack assembly embodiments except that the reference numerals applied todesignate the component parts of the second jack embodiment have beenprimed to distinguish them from the reference numerals used for thefirst embodiment.

The finger stock on printed circuit board 94' may be the same as fingers138-143 on board 94. Accordingly, like reference numerals have beenapplied to designate like fingers except that the reference numerals forthe fingers on board 94 have also been primed to distinguish them fromthe reference characters used in the first illustrated jack embodiment.Fingers 138'-143' are arranged in the same way as previously describedfor fingers 138-143. FIGS. 34 and 35 show only four of the fingers ineach of the six sets of fingers 138', 139', 140', 141', 142' and 143'together with corresponding numbers of connector terminals and printedcircuit tracks to simplify the schematic circuit diagram.

In FIGS. 34 and 35 the terminals of connector 56' are indicated at 294,295, 296, 297, 294a, 295a, 296a and 297a, and the terminals in connector57' are indicated at 298, 299, 300, 301, 298a, 299a, 300a and 301a. Asshown in FIG. 34, a printed circuit 303 provides the various circuitconnections to fingers 138'-140', connector terminals 294-301 andcontact springs 160' and 161'. As shown in FIG. 35, a further printedcircuit 303a provides the various circuit connections to fingers141'-143', connector terminals 294-301a and contact springs 162' and163'. Circuits 303 and 303a are applied directly to board 94'.

Each of the fingers 138' is connected by way of a separate printedcircuit conductor or track 290 to a different one of the terminals294-297 in connector 56'. Similarly, each of the fingers 139' isconnected by way of a separate printed circuit conductor or track 292 toa different one of the terminals 298-301 in connector 57'.

In addition to conductors 290 and 292 the printed circuit pattern 303 isprovided with a first set of contact pads 306 (individually indicated at306-1 and 306-2 in FIG. 34), a second set of contact pads 307(individually indicated at 307-1 and 307-2 in FIG. 34), a third set ofcontact pads 308 (individually indicated at 308-1 and 308-2 in FIG. 34),and a fourth set of contact pads 309 (individually indicated at 309-1and 309-2 in FIG. 34). Each of the contact pads 308 forms a part of adifferent one of the conductors 292. Each of the contact pads 307 isconnected by way of a branch of a different one of the conductors 290 toa different one of the terminals connectors 294-297 as shown.

In the simplified diagram shown in FIG. 34 only two of the contactsprings 160' and only two of the contact springs 161' are shown, thisbeing all that is needed to establish the four normal through circuitsnormally connecting the four connector terminals 294-297 to the fourconnector terminals 298-301, respectively. The two contact springs 160'illustrated in FIG. 34 are individually indicated at 160'-1 and 160'-2.Similarly, the two contact springs 161' in FIG. 34 are individuallyindicated at 161'-1 and 161'-2.

Contact spring 160'-1 has its stationary end or tail 180' seated oncontact pad 306-1 and its deflectible end 182' normally seated oncontact pad 308-1 thus completing a normal through circuit betweenconnector terminals 294 and 298. Similarly, contact spring 160'-2 hasits stationary end 180' seated on contact pad 306-2 and its deflectibleend 182' normally seated on contact pad 308-2, thus completing a normalthrough circuit interconnecting terminals 295 and 299. In a similarfashion contact spring 161'-1 has its stationary end 180' seated oncontact pad 307-1 and its deflectible end 182' normally seated oncontact pad 309-1 to thus normally connect connector terminal 296 toconnector terminal 300. In a like fashion contact spring 161'-2 has itsstationary end 180' seated on contact pad 307-2 and its deflectible end182' normally seated on contact pad 309-2 to thereby normallyinterconnect connector terminals 297 and 301.

As will be described in greater detail below, flap 250 is interengagedwith the two sets of contact springs 160' and 161' and is pivoted byinsertion of a patch cord plug into either one of the plug-receivingsockets 70' and 71' to deflect the deflectible ends 182' of both sets ofcontact springs 160' and 161' away from their respective contact pads totheir circuit-opening positions. As a consequence, the circuitconnections between terminals 294-297 and terminals 298-301 will bebroken.

As shown in FIG. 34, each of the terminals of conductor 57' may beconnected to a different one of the fingers 140' by way of a separateprinted circuit conductor or track 320 to thus establish the monitoringcircuit connection similar to that described for socket 72 in the firstjack embodiment.

As illustrated in FIG. 34, each of the terminals in connector 56' isconnected to its associated terminal in connector 57' by way of only onecontact spring rather than two springs as is the case in the first jackembodiment shown in FIG. 1A. As a result, the total number of contactsprings 160'-163' can be reduced by one half without reducing the numberof normal through circuits or current conducting paths which areprovided in the jack for interconnecting the terminals of connectors 56'and 57'. For example, only six of the contact springs 160' and six ofthe contact springs 161' are needed for establishing twelve normalthrough circuits in the jack.

As will be appreciated from the schematic shown in FIG. 34, the variousprinted circuit conductors 290. 292 and 320 will each be divided intodifferent segments, some being locked on one side of the printed circuitboard 94' and others being located on the opposite side of the printedcircuit board 94' to establish the illustrated circuit connectionswithout having the different conductors interfere with one another. Italso will be appreciated that any suitable pattern or arrangement ofprinted circuit conductors 290, 292 and 320 may be utilized inconjunction with the principles of this invention, the one shown in thedrawings being merely illustrative.

Referring to FIG. 35 the printed circuit pattern 303a for making thevarious circuit connections to fingers 141'-143', connector terminals294a-301a and contact springs 162' and 163' may be the same as theprinted circuit pattern 303 shown in FIG. 34. Accordingly likecomponents of the printed circuits 303 and 303a have been identified bylike reference numerals except that the reference numerals used toidentify the components of printed circuit 303a have been suffixed bythe letter a to distinguish them from the reference numerals used inconjunction with the printed circuit 303.

From the foregoing it will be appreciated that each of the fingers 141'is connected by way of a separate printed circuit conductor 290a to adifferent one of the connector terminals 294a-297a and further that eachof the fingers 142' is connected by way of a separate one of theconductors 292a to a different one of the connector terminals 298a-301a.Furthermore, each of the fingers 143' is connected by way of a separateone of the conductors 320a to a different one of the connector terminals298a-301a.

In FIG. 35 only two of the contact springs 162' and only two of thecontact springs 163' are shown for purposes of simplification similar tothe schematic in FIG. 34. The two contact springs 162' illustrated inFIG. 35 are individually indicated at 162'-1 and 162'-2. Similarly, thetwo contact springs 163' in FIG. 35 are individually indicated at 163'-1and 163'-2.

Similar to the circuit description for FIG. 34 it is apparent from FIG.35 that contact spring 162'-1 lies in contact with contact pads 306-1aand 308-1a, that contact spring 162'-2 lies in contact with pads 306-2aand 308-2a, that contact spring 163'-1 lies in contact with pads 307-1aand 309-1a, and that contact spring 163'-2 lies in contact with pads307-2a and 209-2a. Each of the connector terminals 294a-297a isconnected by a separate one of these contact springs to the terminals298a-301a, respectively. Thus each normal through circuit in the printedcircuit pattern 303a contains only one contact spring as is the casewith printed circuit pattern 303.

As will be described in detail below flap 252 is engaged with the twosets of contact springs 162' and 163' and is pivoted by insertion ofeither one of the patch cord plugs 52 or 53 into either one of theplug-receiving sockets 70' or 71' to deflect the deflectible ends 182'of both sets of contact springs 162' and 163' away from their respectivecontact pads to their circuit-opening positions. All of the circuitsnormally interconnecting the terminals of connectors 56' and 57' willtherefore be opened or broken by insertion of either one of the patchcord plugs 52 or 53 into either one of the plug-receiving sockets 70' or71'.

Additionally, insertion of either one of the patch cord plugs intosocket 70' results in the electrical connection of each of the plug'scontact elements 134 and 136 to a different one of the terminals inconnector 56' by way of the previously described printed circuitconnections. Furthermore, insertion of either one of patch cord plugsinto the plug-receiving socket 71' results in the electrical connectionof each of the plug's contact elements 134 and 136 to a different one ofthe terminals in connector 57' by way of the circuit connections inprinted circuit 303 and 303a.

Referring to FIGS. 22 and 23, housing 82' is the same as housing 82except that the previously described pair of spring-receiving windows onthe left side have been merged to form a single window 254 through thehousing side wall 89. On the opposite side of housing 82' the previouslydescribed pair of spring-receiving windows have also been merged to forma single window 256 through housing side wall 88. Window 254 opens intosockets 70' and 71' on one side of the housing, and window 256 alsoopens into sockets 70' and 71' on the opposite side of the jack housingin registry with window 254.

As shown in FIG. 22 flap 250 is received in window 254 and is formedwith a ribbed body portion 258 and four pairs of pivot arms 260, 261,262 and 263 extending from the forward edge of the flap. Pivot arms260-263 are slidably received in separate grooves that are formedbetween the ribs 218' on window shelf 216'. The pivot arms of each pairare spaced apart by the width of one of the ribs 218' to receive one ofthe ribs. By this construction flap 250 is pivotable about an axisnormally intersecting ribs 218' and pivot arms 260-263 and extendingparallel to the front and rear edges of window 254 and to a medial planecontaining the longitudinal axes of sockets 70'-72'. The pivot axis offlap 250 is perpendicular with respect to springs 160' and 161'.

In addition to pivot arms 260-263 flap 250 is also integrally formedwith two pairs of guide arms 264 and 265 projecting rearwardly from therearwardly facing edge of flap body 258 to slidably receive differentones of the jack housing spacer ribs 219'. As shown in FIGS. 24-27 flap250 is pivotable between two angularly spaced apart positions. In oneposition flap 250 is pivoted inwardly to extend into sockets 70' and71'. In the other position flap 250 is pivoted outwardly to a positionwhere it is out of sockets 70' and 71' and about flush with the outersurface of the jack housing side wall 89'. Partition wall 90' is notchedor cut out at 267 to form a recessed region that allows flap 250 to bepivoted into sockets 70' and 71' without interference. A pair of bars268 and 270 keep flap 250 from canting and from tilting out of window254 at its upper or lower ends upon insertion of a plug into either oneof the sockets 70' or 71'. Bars 268 and 270 may be formed from anysuitable electrical insulating material and are suitably supported onthe housing side wall to span window 254 between the window's forwardand rearward edges 272 and 274 at right angles thereto.

As shown, flap 250 extends full length of window 254 from the upper edgethereof to the lower edge thereof. Additionally, flap 250 is disposedbetween the spring arms 190' and 191' of contact springs 160' and 161'.More specifically, flap 250 lies between the spring segments 194' ofcontact springs 160' and 161' on its outer side and the spring segments200' of contact springs 160' and 161' on its inner side.

The outwardly facing side of flap 250 may be formed with straightparallel spaced apart stiffening ribs 276. As flap 250 is pivotedoutwardly the straight spring segments 194' of springs 160' and 161'will be received between ribs 276 to thereby lie between ribs 276. Theoutward pivotal movement of flap 250 will not result in the deflectionof spring arms 190'.

The inner side of flap 250 is also formed with a group of straightparallel spaced apart stiffening ribs 278 to form a group of parallelspaced apart grooves 280. Rubs 278 extend parallel with ribs 276 andwith the spring arms 191' of contact springs 160' and 161'. An aperture282 is located at the rearward end of each of the grooves 280 and isformed through the flap's rearward edge portion 284.

The spring arm segment 200' of each of the contact springs 160' and 161'is seated in a different one of the flap's grooves 280 on the inner sideof flap 250. These spring arm segments 200' thus lie between and arespaced apart by the ribs 278 on the inner side of flap 250. The springarm transition portion 202' at the rearward end of each spring armsegment 200' slidably passes through the aperture 282 at the end of itsassociated groove 280. By this arrangement the spring segments 201' ofcontact springs 160' and 161' overlie and are disposed outwardly of therearward flap edge portion 284 which lies rearwardly of the straight rowof apertures 282. By this construction the spring arms 191' of contactsprings 160' and 161' link or interengage with flap 250 at its rearwardedge remote from its pivot axis. The nose portions 192' of contactsprings 160' and 161' extend around the forwardly facing pivot edge offlap 250 as shown.

Apart from their interengagement with flap 250, contact springs 160' and161' are arranged in housing 82' and are flexed in the same mannerdescribed from springs 160 and 161 in the first embodiment. The springarms 191' of contact springs 160' and 161' are therefore normally bowedor flexed inwardly toward the printed circuit board 94' in the samemanner as spring arms 191 in the first jack embodiment. As a result, thespring arm segments 201' of contact springs 160' and 161' bear againstthe rearward edge portion 284 of flap 250 to yieldably urge and thuspivot flap 250 inwardly to the position where it normally extends intothe plug-receiving sockets 70' and 71' when no patch cord plug isreceived in either one of the sockets 70' or 71'.

Flap 252 is of the same construction as flap 250. Accordingly, likereference numerals have been applied to designate like portions of thetwo flaps.

As shown in FIG. 23 flap 252 is arranged and pivotally mounted in window256 in the same manner just described for flap 250. Furthermore, thearrangement of flap 252 with contact springs 162' and 163' is the sameas the arrangement just described for flap 250 and contact springs 160'and 161'. Contact springs 162' and 163' are arranged in housing 82' inthe manner described in the first embodiment. The pivot axes of flaps250 and 252 are in parallel spaced apart relation with each other andare arranged in a common plane normally intersecting the longitudinalaxes of sockets 70'-72'. Partition wall 90' is notched or cut away at269 to define a recessed region that permits flap 252 to be pivoted intosockets 70' and 71' without interfering with the partition wall.

By the foregoing construction it will be appreciated that flap 252 ispivoted inwardly under the bias exerted by the contact spring arms 191'of springs 162' and 163' when no patch cord plug is received in eitherone of the sockets 70' or 71'. Accordingly, flaps 250 and 252 convergetoward each other in a rearwardly extending direction to define anoutwardly diverging open mouth within sockets 70' and 71' for receivingeither one of the plugs 52 or 53 upon insertion thereof into either oneof the sockets 70' or 71'. As shown, flaps 250 and 252 together withtheir associated contact springs are symmetrically arranged on oppositesides of a plane containing the longitudinal axes of sockets 70'-72' andmedially intersecting the printed circuit board 94' in parallel relationwith the oppositely facing circuit-bearing sides thereof.

As either one of the patch cord plugs 52 or 53 is inserted into socket70', the forward corners 228 and 229 on plug body 130 will concomitantlyengage flaps 250 and 252 along the inwardly facing sides thereof andthus will travel along the inwardly facing sides of flaps 250 and 252 topivotally urge flaps 250 and 252 outwardly in opposite directions andaway from each other to their extreme positions where they lie outwardlyof sockets 70' and 71' within windows 254 and 256, respectively.

The outward pivotal motion that is imparted to flap 250 by insertion ofa patch cord plug into either one of the sockets 70' or 71' will beagainst the bias of the spring arms 191' of springs 160' and 161' andwill flex and lift these spring arms 191' in unison away from theirrespective contact pads on the printed circuit board 94', therebyelectrically disconnecting the connector terminals 294-297 from theconnector terminals 298-301. At the same time the outward pivotal motionimparted to flap 252 by the insertion of a patch cord plug into eitherone of the sockets 70' or 71' will flex and lift the contact spring arms191' of contact springs 162' and 163' off their respective contact padson the printed circuit board 94' in a similar manner to therebyelectrically disconnect the connector terminals 294a-297a from theconnector terminals 298a-301a. Insertion of either one of the patch cordplugs 52 or 53 into either one of the plug-receiving sockets 70' or 71'therefore results in the electrical disconnection of the terminals ofconnector 56' from the terminals of connector 57'. When the patch cordplug is in its fully inserted circuit-making and circuit-breakingposition within either one of the sockets 70' and 71' flap 250 will liein window 254 against the side face 232 of the plug body 130, and flap252 will similarly lie in window 256 against the side face 233 of plugbody 130.

When the patch cord plug is removed from the plug-receiving socket, thebias exerted by the spring arms 191' of springs 160' and 161' will biasflap 250 inwardly, causing it to pivot about its pivot axis to itsposition shown in FIGS. 24 and 26 where it extends into sockets 70' and71'. Removal of the patch cord plug will also result in the pivotalmovement of flap 252 about its pivot axis under the bias exerted by thespring arms 191' of springs 162' and 163' thus urging flap 252 to itsposition where it also extends into sockets 70' and 71' as shown inFIGS. 24 and 26.

The contact-engaging ends 182' of springs 160'-163' will wipe theirrespective contact pads as they lift off the contact pads and also asthey touch down on the contact pads in the same manner described in thefirst jack embodiment. Additionally, the corners 230' of contact springs160' and 162' will seat in the plug body grooves 234 and 235 uponinsertion of either one of the patch cord plugs 52 or 53 into socket 70'to releaseably lock the plug within socket 70' in the same mannerdescribed in the preceding embodiment. Likewise, the corners 230' ofcontact springs 161' and 163' will seat in the plug body grooves 234 and235 upon insertion of either one of the patch cord plugs 52 or 53 intosocket 71', thereby releasably locking the patch cord plug within socket71' in the manner as previously described.

From the foregoing description it will be appreciated that the contactsprings 160'-163' and the flaps 250 and 252 form a switching means inwhich the contact springs 160'-163' constitute the switching elementsand in which the flaps 250 and 252 constitute switch actuators foractuating the switching elements to their circuit-breaking positions byinsertion of a patch cord plug into either one of the sockets 70' or71'. In the first jack embodiment the switching means has no separateactuator and comprises the contact springs 160-163 which are operated oractuated by direct engagement with the patch cord plug's insulating,contact-carrying body 130.

The type of plug used with the jack of this invention may be referred toas a printed circuit board edge connector or a card edge connector.Coacting rib and groove formations may be formed on the jack housing andthe patch cord plug for keying the patch cord plug so that it can beinserted in only one single predetermined orientation into any one ofthe three plug-receiving sockets 70'-72'.

In assembling the component parts of the jack shown in FIGS. 22-33,springs 160' and 161' may first be assembled or mounted on flap 250 bythreading the spring arms 191' through apertures 282. The sub-assemblyof flap 250 and springs 160' and 161' then is inserted as a unit intowindow 254 after board 94' is inserted and fixed to housing 82' toproperly position flap 250 and springs 160' and 161' on the jackhousing. Bars 268 and 270 are then mounted in place in window 254. Flap252 and springs 162' and 163' may be assembled in the same manner asdescribed above.

Referring to FIGS. 15-19 and 19A plug body 130 has a hollow interior andis formed with a contact-mounting portion 330 and a cable-receivingcollar portion 332 extending rearwardly from the contact-mountingportion 330 at the end of body 130 which is opposite from the body'sopen card-receiving end. Contacts 134 and 136 are suitably mounted inspaced apart relation in portion 330. The multi-conductor cable 54extends coaxially through collar portion 332 to provide for theconnection of its conductors to contact elements 134 and 136.

Collar portion 332 is interiorly formed with a cable-anchoring strainrelief configuration comprising a series of threads 334 and a pair ofdiametrically opposed inwardly opening grooves or channels 336 and 338.Grooves 336 and 338 and threads 334 are formed on the innercable-engaging periphery of collar portion 332. As shown, grooves 336and 338 extend longitudinally with respect to the longitudinal axis ofcollar portion 332 and hence with respect to the axis of the straightcable portion received in collar portion 332.

Threads 334 are disposed inwardly of the rearward end of collar portion332 and are disposed between two cylindrically smooth, uniformlydiametered, cable-receiving bore portions 339 and 341 in collar portion332. The set of threads 334 thus interrupt the smooth walled passagethrough collar portion 332 as shown. The diameters of bore portions 339and 341 are equal and greater than the internal crest diameter ofthreads 334 but smaller than the internal root diameter of threads 334.The internal diameters of bore portions 339 and 341 may be about equalto the diameter at the pitch line of threads 334.

As shown in FIGS. 15, 17, 18, 19 and 19A plug body 130 is longitudinallydivided into two one-piece complementary halves or shells 340 and 342.Shells 340 and 342 are separately molded from any suitable electricalinsulating material and are secured together by suitable fastener meanssuch as screw and nut assemblies 344. Shells 340 and 342 abut along aninterface that is contained in a plane medially intersecting portions330 and 332 and containing the longitudinal axis of collar portion 332such that the two shells form complementary halves of portion 330 andalso complementary halves of portion 332. Threads 334 are thereforedivided into two complementary diametrically opposed segments 346 and348 each having an arcuate extent of 180°.

As shown in FIGS. 19 and 19A groove 336 interrupts the thread segments346, and groove 338 interrupts the thread segment 348. A plane mediallyintersecting both of the grooves 336 and 338 normally intersects theplane containing the interface between shells 340 and 342.

The internal diameters of the bore portion 339 and 341 is about equal tothe outer diameter of cable 54 in its uncompressed, relaxed condition.The crest diameter of threads 334 is therefore significantly less thanthis uncompressed outer cable diameter.

In order to assemble the component parts of the patch cord with the plugconstruction shown in FIGS. 15-19, the circuit connections are firstmade between the conductors of cable 54 and contacts 134 and 136, andthe unstripped portion of the cable with the outer sheath thereon islaid in place on one of the complementary halves of collar portion 332.The two complementary shells 340 and 342 are then tightly securedtogether by the screws 344 to firmly clamp the unstripped portion ofcable 54 between the complementary halves of collar portion 332.

Because the crest diameter of threads 334 is significantly less than theuncompressed outer diameter of cable 54 the plastic deformable outercable sheath (indicated at 350 in FIGS. 8 and 10) is deformed orextruded into the inwardly opening roots of threads 334 and also intothe inwardly opening grooves 336 and 338. Threads 334 thus grip andanchor cable 54 in collar portion 332 to resist tensioning forces thatmay be applied to the cable to pull the cable out of the plug body 130.The deformation or extrusion of the cable sheath 350 into grooves 336and 338 provide a strain relieving interlock or anchor resistingtwisting or turning of cable 54 in collar portion 332. Thus, theinterlock established between the outer cable sheath and threads 334 andgrooves 336 and 338 resists axial withdrawl of the cable and twisting orturning movement of the cable in collar portion 332.

As explained above contact springs 160-163 and 160'-163' are eachindividually removable from their jack assemblies without requiring theremoval of any other part, without requiring any disassembly of the jackand without requiring the disconnection of any connections such assoldering connections or the like. This special contact spring removalfeature permits the quick and easy removal of defective spring members.It is especially useful in situations where one or more springs arefound to be defective upon completing the assembly or are damaged in thecourse of assembly with the other jack parts and thus requirereplacement before use or shipment to a customer.

In practice leads may be used to connect the various printed circuitconductors (particularly the ends of these conductors) to the terminalsin connectors 56, 57, 56' and 57' themselves. The portions of theprinted circuit conductors that connect to these leads or to othernon-printed circuit terminals are considered to be terminal portions.The printed circuits described above therefore have various sets ofterminal portions corresponding in number to the terminals withinconnectors 56, 57, 56' and 57'.

The invention may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. The presentembodiments are therefore to be considered in all respects asillustrative and not restrictive, the scope of the invention beingindicated by the appended claims rather than by the foregoingdescription, and all changes which come within the meaning and range ofequivalency of the claims are therefore intended to be embraced therein.

What is claimed and desired to be secured by Letters Patent is:
 1. Amethod of manufacturing an electrical jack having a housing which isprovided with at least one socket for slidably receiving a printedcircuit board edge connector, a printed circuit board having an endportion extending into said socket for reception in said connector uponinsertion of the connector into said socket, and switching meanscomprising a set of contact spring members normally conditioned tocooperate with a printed circuit on said board for electricallyinterconnecting two sets of the jack's terminals and actuatable inresponse to the reception of the connector in said socket toelectrically disconnect the two sets of terminals from each other, saidmethod comprising the steps of forming said housing with said socket andwith an aperture which extends through a side wall of said housing toopen into the interior of said housing, inserting said board into saidhousing to position said end portion in said socket, securing saidcircuit board to said housing after it is inserted into said housing andinserting said spring members through said aperture to positions in saidhousing where they engage and are removably trapped in place betweensurfaces on said housing and said board.
 2. A method of manufacturing anelectrical jack wherein a housing is formed with at least one sockethaving a first opening at one of its ends for slidably receiving acircuit board edge connector and a second opening at the other of itsends for receiving an end portion of a circuit board, and wherein aplurality of contact elements are positioned on said end portion of saidboard at locations where they make electrical contact with contactelements in said connector when said end portion is received in saidsocket and said connector is inserted into said socket at a positionwhere it receives said end portion, said method comprising the steps ofproviding an aperture in a pre-selected outer wall of said housing,inserting said end portion through said second open end and into saidsocket such that is is disposed at a position where it is spaced fromsaid pre-selected wall, rigidly securing said board to said housingafter said end portion of said board is received in said socket,inserting a plurality of contact spring members through said aperture topositions in said housing where (a) they are removably trapped in placesolely by seating engagement with cooperating surfaces on saidpre-selected wall and said board, (b) they cooperate with conductors onsaid board to electrically interconnect two sets of terminals, and (c)they are deflectably upon insertion of said connector into said socketto electrically disconnect the two sets of terminals from each other. 3.The method defined in claim 2 wherein said contact spring members arearranged in said housing at positions where portions of the contactspring members lie between and yieldably seat against a pair ofopposing, spaced apart surfaces on said housing and said circuit board,respectively.